Good catch. The head is a 4.2 and the header is for a 4.0. Both the header and manifold were a after-thought on the sellers part. The intake manifold is a Offenhauser 4 barrel. Not sure if I want to even use it; haven't done any research on it. Originally planned on using my stock manifolds and doing a junkyard TBI, but I'm a long way from that point, but plans have a way of changing.

Figured, what the hey, if nothing else I can sell them and recoup some of my money.

86 CJ7, 258 Engine, T-177, Dana 300.

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Got most of the parts I needed except for the install kit for the AMC 20. Got a email the kit is backordered, so I'll call tomorrow and find out if it will come in soon or order from somewhere else, or peice together a order of what I need. On the plus side, the front dana 30 is back together.

For the lift kit, planning on going with the BDS 3".

86 CJ7, 258 Engine, T-177, Dana 300.

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I found the AMC 20 rebuild kit (Timken) at Autozone, have you tried them?

I thought I'd need a full kit, but my pinion and carrier bearings I pulled out of one the craigslist axles are in perfect shape. Looks like the axle was rebuilt not long ago. Even though it was sitting in a field, the oil was still good with no water intrusion. I tried to order the Superior diff installation kit which comes with Pinion Nut, Pinion Seal, Crush Sleeve, Pinion Shims, Carrier Shims, Ring Gear Bolts, Locite, Marking Compound, Brush and Gasket, but no joy.

I did pick up some extra crush sleeves and a diff seal, so the only thing I really need are the ring bolts and should be able to find them in town. I probably have enought shims to do what I need, so hopefully I can get moving on it this week.

86 CJ7, 258 Engine, T-177, Dana 300.

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Been busy with family and work for the last few weeks and waiting on parts. Finally got everything together and got the R&P in and balanced out. Man, that crush spacer was a bear! Took about a week of shimming, testing, shimming and more testing. Finally got a good pattern.

Today started to install the Superior axles. Everything went fine until i started to press the bearings on. Got the normal popping as the bearing pressed on and then BANG. Race cracked and everything went flying. No idea why the bearing blew up, so figured I try the other axle. This time, went slower and more carefully. When the bearing was about 3/4 of the way pressed on, BANG. Happened again. . NAPA has the bearings, but of course they are closed until Monday.

Is there a trick to pressing these bearings on? Heat?. Right now, I'm probably just going to drop everything off at a machine shop on Monday and get them to press the bearings on.

Tomorrow I can work on the engine. Picked up new lifters, pushrods and have all the seals, so I'll mate the head, install the oil pan and start cleaning off the orange paint so i can get a good coat of epoxy primer. Still haven't decided on the final color.

86 CJ7, 258 Engine, T-177, Dana 300.

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Started putting together the engine; got the rear seal and lifters in, cleaned the surfaces up and ready to install the head. I ordered new head bolts and they arrived Friday. Box say AMC 258, but turns these are for a different 258. All the bolts same length and 1/2 inch. Found what I need at headbolts.com. Lesson learned - research, research, research. My fault as had I searched the forum, I would have found someone else who had the same problem. Oh well, just one of the joys of building a jeep.

86 CJ7, 258 Engine, T-177, Dana 300.

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Local NAPA machine shop pressed my axle bearings on and I finished the AMC 20 up except for paint. Seems to operate nice and smooth, but the real test happens when rubber turns . Not much else accomplished except cleaning up a bunch of smaller parts for prime and paint this weekend. I ordered headbolts and the accessory bolt kit from headbolts.com on last monday. Suppossed to ship USPS priority mail, so I hope they get here today or tomorrow. If not, I'll keep plugging away with wire wheels on other parts.

86 CJ7, 258 Engine, T-177, Dana 300.

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Hadn't seen your progress for a while. Thought I subscribed but hadn't. That'll change.

Your progress is looking great. The frame really turned out nice. Did you ever figure out why those 2 bearings craked when you pressed them on? Keep us posted!!

Thanks for the frame comment. On the bearings, I talked to my NAPA machine guy and he showed me the problem. On the axle is a small step where the bearing is suppossed to stop at. The bearing, a SET9, has a small chamfer on the inner edge instead of a corner, so instead of butting up against the step, it starts to ride over it. Just a little too much pressure and POW. His shop press has a guage and soon as he saw the pressure rise, he knew the bearing was seated. After he told me he's busted more than a few, even with the gauge, I didn't feel so bad. Even now that I know the problem and I have to install these bearings again, I'll probably take them to his shop. Bearings are $35 each, so the $10 charge to do it right the first time is well worth it.

86 CJ7, 258 Engine, T-177, Dana 300.

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Started out the day wire wheeling and stripping various parts. Just when I was almost ready to quit, USPS showed up with my head bolts.

1st pic is the pile of parts, including the AMC 20 I need to prime and paint. Way too moist here today, so I'll add some more to the pile and paint first chance the weather breaks. Charley's ready to quit for the day as well.

2nd pic is one of my motor mount brackets. You can see a nice crack, so I'll have to fire up the welder and fix it. Still have to do a little welding on my transmission crossmember, so I'll do it all at one time.

Last pic it the almost assembled motor. Still have to get a water pump gasket. The valve cover is a plastic piece of junk, but it'll keep stuff out of the engine when I strip off the ugly orange paint.

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86 CJ7, 258 Engine, T-177, Dana 300.

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Still had some work to be done on the transmission cross-member, so figured I'd knock it out.

First pic is the handy work done by a PO. For some reason, he decided to cut out a portion of the metal. Originally the cross-member had some extra metal welded on the side, several cracks and was bent. Got the metal cut off and straightened out a while back and checked the fit to the frame.

Second pic is one of the patches. I tried to keep the radius as close to original for the drive-shaft clearance.

Third pic, both patches cut to fit and tacked in.

Last pic, finished product.

I sprayed Osphro on it and the other parts I had ready and will let them dry overnight.

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86 CJ7, 258 Engine, T-177, Dana 300.

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I just read the 4 pages of this thread and love where this is going. I live up off 2301 in Bayou George and work in the Springfield area. If you ever need an extra pair of hands hollar at me and I'll try to help all I can.
My 94 is a lil slower build than yours, but it'll get there..